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Abstract:

A golf club head having a face component, a crown, and a composite sole
or a composite body patch with one or more weight ports for receiving one
or more weight inserts is disclosed herein. At least part of each of the
weight ports is integrally formed in the composite sole or composite body
patch, and each of the weight ports include a weight receiving region for
receiving a weight and a screw receiving region for receiving a screw
that secures the weight in the weight port.

Claims:

1. A wood-type golf club head comprising: a metal face component
comprising a striking surface and a face extension an aft body comprising
a crown, a sole, an interior surface, an exterior surface, and a cutout
portion; and a composite body patch comprising an interior surface, an
exterior surface, and at least one, integrally formed weight port,
wherein the weight port comprises a composite component and a metal boss,
and wherein the composite body patch is affixed to the aft body and
covers the cutout portion.

2. The wood-type golf club head of claim 2, wherein the metal boss is
affixed to the interior surface of the composite body patch.

3. The wood-type golf club head of claim 2, wherein the metal boss is
affixed to the exterior surface of the composite body patch.

4. The wood-type golf club head of claim 1, wherein the aft body further
comprises a ledge surrounding the cutout portion, and wherein a portion
of the interior surface of the composite body patch is affixed to the
exterior surface of the ledge with an adhesive.

5. The wood-type golf club head of claim 1, wherein the composite body
patch further comprises a ledge, and wherein the exterior surface of the
ledge is affixed to the interior surface of the aft body with an
adhesive.

6. The wood-type golf club head of claim 1, further comprising a weight
insert, wherein the weight insert is affixed to the weight port with a
screw.

7. The wood-type golf club head of claim 6, wherein the weight port has a
conical shape and wherein the weight insert has a shape that fits within
the weight port.

8. The wood-type golf club head of claim 1, further comprising a weight
screw comprising a head portion and a screw portion.

9. The wood-type golf club head of claim 8, wherein the weight screw has
a weight of at least 1 gram and no more than 20 grams.

10. The wood-type golf club head of claim 1, wherein the golf club head
is a driver having a volume of 400 to 500 cubic centimeters.

11. A golf club head comprising: a metal face component; an aft body
comprising a crown, a sole, and a cutout portion; a composite body patch;
a threaded boss composed of a metal material; and a weight screw, wherein
the composite body patch comprises an exterior surface, an interior
surface, and at least one, integrally formed weight port, wherein the
threaded boss is affixed to the at least one weight port with an
adhesive, wherein the composite body patch is affixed to the aft body
with an adhesive and covers the cutout portion, and wherein the golf club
head has a volume of 400 to 500 cubic centimeters.

12. The golf club head of claim 11, wherein the cutout portion is located
on a toe section of the aft body.

13. The golf club head of claim 11, wherein the face component and the
aft body are composed of a titanium alloy.

14. The golf club head of claim 11, wherein the crown is composed of a
composite material, the sole is composed of a metal alloy, and the cutout
is located on the sole.

15. The golf club head of claim 11, wherein the aft body comprises at
least one integrally formed weight port.

16. The golf club head of claim 11, wherein the composite body patch has
an asymmetrical shape.

17. The golf club head of claim 11, wherein the aft body further
comprises a ledge surrounding the cutout portion, and wherein the
interior surface of the composite body patch is affixed to the exterior
surface of the ledge.

18. The golf club head of claim 11, wherein the composite body patch
further comprises a ledge, and wherein the external surface of the ledge
is affixed to the interior surface of the aft body.

19. A driver-type golf club head comprising: a face component comprising
a striking surface and a return portion, the face component composed of a
titanium alloy; an aft body comprising a toe side, a heel side, a crown,
a sole, and a cutout portion, the aft body composed of a titanium alloy;
a composite body patch comprising an exterior surface, an interior
surface, a ledge, and at least one, integrally formed weight port; a
threaded boss composed of a metal material; and a weight screw comprising
threads sized to fit within the threaded boss, wherein the threaded boss
is affixed to the weight port, wherein an exterior surface of the ledge
is affixed to the interior surface of the aft body with an adhesive
material such that the composite patch fully covers the cutout portion,
and wherein the golf club head has a mass of 180 grams to 215 grams.

20. The driver-type golf club head of claim 19, wherein the cutout
portion is located in the sole proximate a toe side of the golf club
head.

Description:

CROSS REFERENCES TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. patent
application Ser. No. 13/248,855, filed on Sep. 29, 2011, which claims
priority to U.S. Provisional Application No. 61/388,124, filed on Sep.
30, 2010, and is a continuation-in-part of U.S. patent application Ser.
No. 12/940,371, filed on Nov. 5, 2010, which claims priority to U.S.
Provisional Application No. 61/286,971, filed on Dec. 16, 2009, each of
which is hereby incorporated by reference in its entirety herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The present invention relates to a golf club head having a
composite sole or composite body patch with one or more weight ports to
house one or more removable weights. More specifically, the present
invention relates to a golf club head having a composite sole or
composite body patch with integrally formed weight ports and a removable,
metal weight insert.

[0005] 2. Description of the Related Art

[0006] As driver golf club heads have increased in volume to greater than
300 cubic centimeters, their moments of inertia have also increased,
providing greater forgiveness for off-center hits. The conventional
method for enlargement of golf club heads was to maximize the spatial
distribution of mass in all three orthogonal orientations. Although this
approach was effective in increasing the moments of inertia of the golf
club heads, it also resulted in the center of gravity of the golf club
head being positioned substantially rearward from the front face of the
golf club head.

[0007] As the center of gravity is positioned further rearward from the
front face, deleterious effects result for shots struck off-center from
the sweet spot of the golf club head. Increased gear effect is the main
cause of the deleterious effects. For heel-ward or toe-ward off-center
hits, the increased gear effect can cause increased side-spin, which
increases dispersion, reduces distance and reduces robustness of ball
flight. For off-center hits above the sweet spot, the increased gear
effect causes reduced backspin, which can cause an undesirable trajectory
having insufficient carry length or time of flight, which in turn can
result in reduced distance and reduced robustness.

[0008] In addition, the same conventional golf club head designs are
limited with regard to the maximum face area, both physical and practical
limitations. The physical limitation is due to the golf club head having
insufficient mass to both increase the length and width of the golf club
head and also to increase the face size without exceeding the upper range
of the preferred total golf club head mass. Such mass distributions are
dependent on minimum wall thickness values required to achieve acceptable
in-service durability.

[0009] The practical limitation is that as the face size is increased, hit
locations in certain regions around the face perimeter will yield an
unsatisfactory ball flight due to the above-mentioned deleterious
effects, which are accentuated for larger faces. The deleterious effects
increase in a non-linear manner as the distance from the face center
increases. Thus the incremental face area gained by increasing face size
will be subject to more extreme deleterious effects. This limits the
practical length of the club, because probable hit distribution across
the surface of the face broadens as the club length increases. As a
result, a longer club will yield a larger percentage of hits in the
perimeter regions of the face where the deleterious effects occur. This
offsets the otherwise beneficial effect of increased head speed. As club
length increases, head speed increases up to a length of approximately 52
inches, at which point aerodynamic and biomechanical effects offset the
length effect.

[0010] Further, conventional head designs having a center of gravity
positioned substantially rearward from the face are subject to
significant dynamic loft effects, which can be undesirable. Dynamic loft
increases with head speed, so that golfers with higher head speeds
experience more dynamic loft than those with slower swing speeds. This is
opposite of what is desired as higher head speeds generally require less
loft, otherwise excess backspin will be generated, which negatively
affects trajectory and performance.

[0011] Currently, golf club heads made of metal, composite, or other
material are produced with a specific weight which is fixed once the golf
club head is finished. The fixed weight of the golf club head determines
the center of gravity and moment of inertia. After the golf club head is
finished, there exists a small amount of weight which needs to be
adjusted. This small amount of weight is called the swing weight.
Presently, if the swing weight needs to be adjusted, to alter the center
of gravity and/or moment of inertia, the fixed weight must be changed,
which requires the manufacture of a new golf club head.

[0012] One invention that addresses a golf club head with an improved
moment of inertia and center of gravity is U.S. Pat. No. 7,559,851 issued
to Cackett et al. for Golf Club Head with High Moment of Inertia. This
patent discloses a golf club head with a moment of inertia, Izz, about
the center of gravity of the golf club head that exceeds 5000
grams-centimeters squared.

[0013] Another example is U.S. Pat. No. 3,897,066 to Belmont which
discloses a wooden golf club head having removably inserted weight
adjustment members. The members are parallel to a central vertical axis
running from the face section to the rear section of the club head and
perpendicular to the crown to toe axis. The weight adjustment members may
be held in place by the use of capsules filled with polyurethane resin,
which can also be used to form the faceplate. The capsules have openings
on a rear surface of the club head with covers to provide access to
adjust the weight means.

[0014] Yet another example is U.S. Pat. No. 2,750,194 to Clark which
discloses a wooden golf club head with weight adjustment means. The golf
club head includes a tray member with sides and bottom for holding the
weight adjustment preferably cast or formed integrally with the heel
plate. The heel plate with attached weight member is inserted into the
head of the golf club via an opening.

[0015] Although the prior art has disclosed many variations of golf club
heads with weight adjustment means, the prior art has failed to provide a
club head with both a superior material construction and a
high-performance weighting configuration.

BRIEF SUMMARY OF THE INVENTION

[0016] It is the object of this invention to adjust the swing weight of
the golf club head externally, without having to manufacture or purchase
a new golf club head. A golfer using the present invention will be able
to adjust the center of gravity and moment of inertia to best suit his or
her playing needs. The golf club head has external weights positioned at
specific locations on the golf club head body to improve the center of
gravity and moment of inertia characteristics. The weights to be inserted
into the cavities of the golf club head all may be of the same size and
shape, however will vary in density. This allows for the weights to be
interchangeable depending on the golfer's individual needs. The aft-body
of the golf club head is preferably composed of a composite material with
recessed cavities to engage the weights. Alternatively, the aft-body
comprises a cutout covered by a body patch composed of composite material
having one or more recessed cavities to engage the weights.

[0017] One aspect of the invention is a golf club head comprising a face
component, a crown, and a composite sole having exterior and interior
surfaces, wherein the composite sole includes at least one weight port.
In another embodiment of the invention, the weight port comprises a
composite component and a metal component. In yet a further embodiment of
the invention, the metal component is affixed to the interior surface of
the composite sole. In a further embodiment of the invention, the golf
club head comprises a weight insert, wherein the weight insert is affixed
to the weight port with a screw. In yet another embodiment of the
invention, the weight insert is composed of a metal material. In an
alternative embodiment of the invention, the screw is composed of a metal
material. In a further embodiment of the present invention, the weight
port has a conical shape and the weight insert has a shape that fits
within the weight port. In a further embodiment of the present invention,
the weight insert has a conical shape.

[0018] Another aspect of the present invention is a golf club head
comprising a metal face component, a crown, a composite sole, and a metal
weight insert having a conical shape, wherein the composite sole has at
least one, integrally formed weight port, wherein the weight port is
conical in shape, wherein the weight port has a metal screw receiving
component, and wherein the weight insert is affixed to the weight port
with a metal screw. In another embodiment, the metal screw receiving
component is threaded. In yet another embodiment, the metal screw
attaches to the metal screw receiving component and thereby secures the
weight insert in the weight port. In a further embodiment, the face
component is composed of titanium. In another embodiment, the crown is
composed of titanium. In yet another embodiment, the crown is composed of
composite material. In another embodiment, the sole has at least three
integrally formed weight ports and at least three metal weight inserts.
In another embodiment, the golf club is a driver. In yet another
embodiment, the golf club is a fairway wood.

[0019] Another aspect of the present invention is a wood-type golf club
head comprising a metal face component comprising a striking surface and
a face extension, an aft body comprising a crown, a sole, an interior
surface, an exterior surface, and a cutout portion, and a composite body
patch comprising an interior surface, an exterior surface, and at least
one, integrally formed weight port, wherein the weight port comprises a
composite component and a metal boss, and wherein the composite body
patch is affixed to the aft body and covers the cutout portion. In some
embodiments, the metal boss may be affixed to the interior surface of the
composite body patch. In other embodiments, the metal boss may be affixed
to the exterior surface of the composite body patch. In another
embodiment, the aft body may further comprise a ledge surrounding the
cutout portion, and a portion of the interior surface of the composite
body patch may be affixed to the exterior surface of the ledge with an
adhesive. In some embodiments, the composite body patch may further
comprise a ledge, and the exterior surface of the ledge may be affixed to
the interior surface of the aft body with an adhesive. This embodiment
may further comprise a weight insert affixed to the weight port with a
screw. The weight port may have a conical shape and the weight insert may
have a shape that fits within the weight port. In an alternative
embodiment, the present invention may further comprise a weight screw
comprising a head portion and a screw portion, which may have a weight of
at least 1 gram and no more than 20 grams. This embodiment may be a
driver having a volume of 400 to 500 cubic centimeters.

[0020] Another aspect of the present invention is a golf club head
comprising a metal face component, an aft body comprising a crown, a
sole, and a cutout portion, a composite body patch, a threaded boss
composed of a metal material, and a weight screw, wherein the composite
body patch comprises an exterior surface, an interior surface, and at
least one, integrally formed weight port, wherein the threaded boss is
affixed to the at least one weight port with an adhesive, wherein the
composite body patch is affixed to the aft body with an adhesive and
covers the cutout portion, and wherein the golf club head has a volume of
400 to 500 cubic centimeters. The cutout portion may be located on a toe
section of the aft body. In some embodiments, the face component and the
aft body may be composed of a titanium alloy. In other embodiments, the
crown may be composed of a composite material, the sole may be composed
of a metal alloy, and the cutout may be located on the sole. The aft body
may in some embodiments comprise at least one integrally formed weight
port. In other embodiments, the composite body patch may have an
asymmetrical shape. In yet another embodiment, the aft body may further
comprise a ledge surrounding the cutout portion, and the interior surface
of the composite body patch may be affixed to the exterior surface of the
ledge. In an alternative embodiment, the composite body patch may
comprise a ledge, and the external surface of the ledge may be affixed to
the interior surface of the aft body.

[0021] Another aspect of the present invention is a driver-type golf club
head comprising a face component comprising a striking surface and a
return portion, the face component composed of a titanium alloy, an aft
body comprising a toe side, a heel side, a crown, a sole, and a cutout
portion, the aft body composed of a titanium alloy, a composite body
patch comprising an exterior surface, an interior surface, a ledge, and
at least one, integrally formed weight port, a threaded boss composed of
a metal material, and a weight screw comprising threads sized to fit
within the threaded boss, wherein the threaded boss is affixed to the
weight port, wherein an exterior surface of the ledge is affixed to the
interior surface of the aft body with an adhesive material such that the
composite patch fully covers the cutout portion, and wherein the golf
club head has a mass of 180 grams to 215 grams. In some embodiments, the
cutout portion may be located in the sole proximate a toe side of the
golf club head.

[0022] Having briefly described the present invention, the above and
further objects, features and advantages thereof will be recognized by
those skilled in the pertinent art from the following detailed
description of the invention when taken in conjunction with the
accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0023]FIG. 1 is sole-side view of a golf club head according to an
embodiment of the present invention.

[0024]FIG. 2 is a heel-side view of the golf club head shown in FIG. 1.

[0027]FIG. 5 is a cross-sectional view of the weight port and golf club
head shown in FIG. 4 along line A-A.

[0028] FIG. 6 is a side perspective view of a weight insert that can be
used with the golf club head shown in FIG. 1.

[0029]FIG. 7 is a cross-sectional view of an alternative configuration of
the weight port and golf club head shown in FIG. 4 along line A-A.

[0030] FIG. 8 is a side plan view of an alternative weight that can be
used with the golf club head of the present invention.

[0031]FIG. 9 is a bottom, rear perspective view of a second embodiment of
the present invention with an exposed cutout portion.

[0032]FIG. 10 is a bottom, toe-side perspective view of the embodiment
shown in FIG. 9 with the cutout portion covered by a composite body
patch.

[0033] FIG. 11 is top perspective view of a third embodiment of the
present invention with an exposed cutout portion.

[0034]FIG. 12 is a bottom, toe-side perspective view of the embodiment
shown in FIG. 11 with the cutout portion covered by a composite body
patch.

[0035]FIG. 13 is a rear perspective view of an embodiment of a composite
body patch of the present invention.

[0036]FIG. 14 is a cross-sectional view of the composite body patch shown
in FIG. 13 along lines 14-14.

[0037]FIG. 15 is a rear perspective view of another embodiment of a
composite body patch of the present invention.

[0038]FIG. 16 is a cross-sectional view of the composite body patch shown
in FIG. 15 along lines 16-16.

[0039]FIG. 17 is a rear perspective view of another embodiment of a
composite body patch of the present invention.

[0040] FIG. 18 is a cross-sectional view of the composite body patch shown
in FIG. 17 along lines 18-18.

[0041]FIG. 19 is a rear perspective view of another embodiment of a
composite body patch of the present invention.

[0042]FIG. 20 is a cross-sectional view of the composite body patch shown
in FIG. 19 along lines 20-20.

DETAILED DESCRIPTION OF THE INVENTION

[0043] The present invention is generally directed to a golf club head
with one or more weight ports that are formed in a composite sole or a
composite sole patch and house removable weight inserts. In the preferred
embodiments, the one or more weight ports are integrally formed in the
sole or body patch.

[0044] Views of the preferred embodiment of the present invention are
shown in FIGS. 1-5. The golf club head 40 shown in FIGS. 1-3 has a hollow
interior 90, shown in FIG. 5, and is generally composed of a face
component 30 comprising a face 60, a face extension 65, and a hosel 50,
and an aft body 70 comprising a crown 62 and a sole 64 having three
weight ports 80, 82, 84. In alternative embodiments, the golf club head
40 may have one, two, or more than three weight ports. The club head 40
also may optionally have a ribbon, skirt, or side portion (not shown)
disposed between the crown 62 and sole 64 portions. The golf club head 40
is preferably partitioned into a heel section 66 nearest the hosel 50, a
toe section 68 opposite the heel section 66, and a rear section 75
opposite the face component 60. The preferred embodiment of the golf club
head 40 shown in FIGS. 1-5 has a volume of approximately 460 cubic
centimeters and a face 60 with a characteristic time that is close to,
but does not exceed, 257 μs.

[0045] In the preferred embodiment shown in FIGS. 1-5, the face component
30 is made of titanium and the aft body 70 (including the crown 62 and
sole 64) is made of a composite material. The composite crown 62 and sole
64 may be formed using one or more of the techniques described in U.S.
Patent Publication Nos. 20100139079 and 20110065528, and U.S. patent
application Ser. No. 12/886,773, the disclosures of which are hereby
incorporated by reference in their entireties herein.

[0046] At least part of each weight port 80, 82, 84 is integrally formed
in the composite sole 64. As shown in FIGS. 4 and 5, the weight port 82
comprises a weight receiving region 100 and a screw-receiving region 105.
In the preferred embodiment, the weight receiving region 100 is the
portion of the weight port 82 that is integrally formed in the composite
and the screw-receiving region 105 is a separate metal piece, e.g., a
screw-receiving boss with internal threads, which is affixed to the
interior surface 102 of the composite weight receiving region 100. The
screw-receiving region 105 preferably is affixed to the interior surface
102 of the composite weight receiving region 100 with an adhesive or
another means.

[0047] The screw-receiving region 105 may also, in an embodiment shown in
FIG. 7, be affixed to the exterior surface 103 of the composite weight
receiving region 100 with an adhesive or with a mechanical fastener such
as a nut 90, which is affixed to a lower portion of the screw-receiving
region 105 to effectively sandwich the weight-receiving region 100
between the screw-receiving region 105 and the nut 90. In this
embodiment, the screw-receiving region 105 rests against the exterior
surface 103 of the weight receiving region 100 and extends into the golf
club head. If the screw-receiving region 105 is mechanically affixed to
the weight receiving region 100 in this manner, it is preferable for an
exterior surface of the screw-receiving region 105 to have threads so
that the nut 90 can securely engage with the screw-receiving region 105.
Other techniques of affixing the screw-receiving region 105 to the
composite weight receiving region 100 may be utilized. In alternative
embodiments, the screw-receiving region 105 may be composed of a material
other than metal, such as composite or plastic.

[0048] As shown in FIG. 5, a weight 200 is placed into the weight port 82
and received by the composite weight receiving region 100. The weight 200
is secured within the weight port 82 with a screw 210. The weight 200 may
be removed from the weight port 82 by unscrewing the screw 210 and
removing both the screw 210 and the weight 200 from the weight port 82.

[0049] In the preferred embodiment, the weight ports 80, 82, 84 are shaped
to receive a conical weight. Also in the preferred embodiment, the weight
200 is conical in shape with a central aperture 205 for receiving a screw
210, as shown in FIG. 6, and both the weight 200 and the screw 210 are
composed of a metal material. The weight 200 and screw 210 may, in
alternative embodiments, be composed of other materials, such as
composite or plastic. In some embodiments, the weight 200 and/or screw
210 may be made of stainless steel, titanium, tungsten, or other metal
materials. In an alternative embodiment, the weight 200 may be a
different shape, such as asymmetric or cylindrical instead of conical,
and may comprise an integrally formed screw portion 220 as shown in FIG.
8, which makes a separate screw 210 unnecessary. In the embodiment shown
in FIG. 8, the weight 200 is a weight screw having an integrally formed
screw portion 220 and a cylindrical head portion 230.

[0050] The weight 200 preferably ranges in mass between 1 grams and 40
grams, more preferably between 10 grams and 30 grams, and most preferably
15 grams to 25 grams. More specifically, if the weight 200 is chosen for
insertion in the toe-section 68 weight port 80, the weight 200 preferably
ranges in mass between 5 grains and 25 grams, more preferably between 6
grams and 20 grams, and most preferably 6 grams to 16 grams. More
specifically, if the weight 200 is chosen for insertion in the heel
section 66 weight port 84, the weight 200 preferably ranges in mass
between 10 grams and 40 grams, more preferably between 10 grams and 30
grams, and most preferably 12 grams to 29 grams. More specifically, if
the weight 200 is chosen for insertion in the rear section 75 weight port
82, the weight 200 preferably ranges in mass between 10 grams and 40
grams, more preferably between 15 grams and 30 grams, and most preferably
23 grams.

[0051] Other embodiments of the present invention are shown in FIGS. 9-12.
In these embodiments, only a portion of the aft body 70, specifically a
body patch 300, is formed of a composite material. The remainder of the
aft body 70, which includes a cutout portion 77 in the sole 64 near the
toe section 68 of the club head 40, can be composed of any material, but
is most preferably composed of a metal alloy, and most preferably a
titanium alloy such as 6-4 titanium. The aft body 70 includes a ledge 72
against which the composite body patch 300 rests and to which the
composite body patch 300 is bonded. In alternative embodiments, discussed
in greater detail herein, the composite body patch 300 may comprise a
ledge 305 instead of or in addition to the aft body 70 ledge 72. In
alternative embodiments, the cutout portion 77 may be located in an area
of the aft body 70 other than the toe section 68. The composite body
patch 300 may be formed using one or more of the techniques described in
U.S. Patent Publication Nos. 20100139079 and 20110065528, and U.S. patent
application Ser. No. 12/886,773, and includes an integrally formed weight
port 350 similar or identical to the one described with reference to the
embodiments shown in FIGS. 1-5.

[0052] As shown in FIGS. 9-12, the composite body patch 300, which
preferably has an asymmetric, teardrop shape (but can be manufactured to
have any desired shape), is sized to completely cover the cutout portion
77 of the aft body 70, thus preventing dirt and debris from entering the
golf club head 40. The composite body patch 300 preferably is permanently
affixed to the aft body 70 with an adhesive material. The cutout portion
77 preferably is circumscribed entirely by the material of the sole 64,
as shown in FIGS. 9 and 10, but in an alternative embodiment it may be
enclosed by the sole 64 on only one or two sides, as shown in FIGS. 11
and 12. In both of these structures, the crown (not shown) may be
integrally cast with the rest of the club head, or it may be affixed to
the club head 40 after the composite body patch 300 has been bonded to
the sole 64. The crown used with this embodiment is preferably composed
of a metal alloy material, but it may instead be a composite material
formed using one or more of the techniques referenced above.

[0053] The composite body patch 300 shown in FIGS. 9-12 may be formed to
have a consistent shape and size, such that it can be mass-produced for
use in many different club heads. The composite body patch 300 is
preferably formed with a ledge 305 to assist in alignment with the aft
body 70 of the golf club head 40. The weight port 350 of the composite
body patch 300 may have different features, as shown in FIGS. 13-20. In
particular, the metal screw-receiving boss 105 may have different
configurations and can be affixed to the weight receiving region 100 of
the weight port 350 in different ways. The manner in which the metal
screw-receiving boss 105 is affixed to the weight port 350 can affect
both the durability of the weight port 350 and the retention of the
weight 200 within the weight port 350. The features shown in FIGS. 13-20
may be applied to the weight ports 80, 82, 84 disclosed in connection
with the preferred embodiment shown in FIGS. 1-5 in addition to the
weight port 350 disclosed in connection with the composite body patch
300.

[0054] As shown in FIGS. 14, 16, and 18, the metal screw-receiving boss
105 preferably has an upper flange 106 and an internal bore 110 with
threads sized to receive either a screw 210 or the integrally formed
screw portion 220 of a weight screw. The metal screw-receiving boss 105
preferably is a single piece of metal that is either cast, forged, or
machined to have the features described herein. In the embodiment shown
in FIGS. 13 and 14, the upper flange 106 of the metal screw-receiving
boss 105 is affixed to an interior surface 352 of the weight receiving
region 100 of the integrally formed weight port 350. The flange 106
preferably rests against and is bonded to the interior surface 352 with a
strong adhesive material. In this configuration, the weight 200, or the
cylindrical head portion 230 of a weight screw, never directly touches
the metal screw-receiving boss 105, as it is separated from the boss 105
by the composite material of the weight receiving region 100.

[0055] In the embodiment shown in FIGS. 15 and 16, the metal
screw-receiving boss 105 has a slight "T" shape such that an upper
portion 107 extends partly into the weight receiving region 100 of the
integrally formed weight port 350. This configuration provides a greater
contact surface between the metal screw-receiving boss 105 and the weight
port 350, and thus decreases the likelihood that the boss 105, and thus
the weight 200, will detach from the weight port 350. The weight 200 will
have minimal contact with the boss 105 at the upper portion 107, so a
user may wish to insert a washer or o-ring into the weight port 350 to
prevent unwanted friction. In this embodiment, the flange 106 rests
against and is bonded to the interior surface 352 of the weight receiving
region 100 of the weight port 350. As shown in FIG. 15, the interior
surface 352 of the weight receiving region 100 has a depression 355 that
is sized to receive the flange 106, and also has keyed sides 340 to
prevent the metal screw-receiving boss 105 from twisting once it is
placed and bonded within the depression 355.

[0056] The embodiment shown in FIGS. 17 and 18 is similar to the one shown
in FIG. 7, as the flange 106 of the metal screw-receiving boss 105 rests
against and is bonded to the exterior surface 353 of the weight receiving
region 100. In this embodiment, however, the weight receiving region 100
of the weight port 350 has a tube portion 345 extending away from the
weight port 350. The metal screw-receiving boss 105 is received within
and bonded to the tube portion 345, thus providing significant contact
and bonding surface to prevent the boss 105 from disengaging from the
weight port 350. In this configuration, the weight 200 directly contacts
the boss 105, so a user can place a washer between the boss 105 and the
weight 200 to prevent unwanted friction.

[0057] The embodiment shown in FIGS. 19 to 20 is similar to the embodiment
shown in FIGS. 18 and 19, as the weight port 350 also includes the tube
portion 345. The boss 105 in this embodiment, however, is much smaller
than in the other embodiments because it lacks a flange 106, and is
retained entirely within the tube portion 345. This configuration reduces
the amount of material needed to form the boss 105, and thus reduces the
overall weight of the weight port 350. Furthermore, since the weight 200
will have only minimal contact with the boss, a washer or o-ring is not
needed to reduce friction.

[0058] In other embodiments, the face component 30 and crown 62 may be
made from cast or forged metals or from composite materials, and may be
formed integrally or pieced together. In yet other embodiments, the face
component 30 and crown 62 each may be composed of different materials.
The golf club of the present invention may also have material
compositions such as those disclosed in U.S. Pat. Nos. 6,244,976,
6,332,847, 6,386,990, 6,406,378, 6,440,008, 6,471,604, 6,491,592,
6,527,650, 6,565,452, 6,575,845, 6,478,692, 6,582,323, 6,508,978,
6,592,466, 6,602,149, 6,607,452, 6,612,398, 6,663,504, 6,669,578,
6,739,982, 6,758,763, 6,860,824, 6,994,637, 7,025,692, 7,070,517,
7,112,148, 7,118,493, 7,121,957, 7,125,344, 7,128,661, 7,163,470,
7,226,366, 7,252,600, 7,258,631, 7,314,418, 7,320,646, 7,387,577,
7,396,296, 7,402,112, 7,407,448, 7,413,520, 7,431,667, 7,438,647,
7,455,598, 7,476,161, 7,491,134, 7,497,787, 7,549,935, 7,578,751,
7,717,807, 7,749,096, and 7,749,097, the disclosure of each of which is
hereby incorporated in its entirety herein.

[0059] The golf club head of the present invention may be constructed to
take various shapes, including traditional, square, rectangular, or
triangular. In some embodiments, the golf club head of the present
invention takes shapes such as those disclosed in U.S. Pat. Nos.
7,163,468, 7,166,038, 7,169,060, 7,278,927, 7,291,075, 7,306,527,
7,311,613, 7,390,269, 7,407,448, 7,410,428, 7,413,520, 7,413,519,
7,419,440, 7,455,598, 7,476,161, 7,494,424, 7,578,751, 7,588,501,
7,591,737, and 7,749,096, the disclosure of each of which is hereby
incorporated in its entirety herein.

[0060] The golf club head of the present invention may also have variable
face thickness, such as the thickness patterns disclosed in U.S. Pat.
Nos. 5,163,682, 5,318,300, 5,474,296, 5,830,084, 5,971,868, 6,007,432,
6,338,683, 6,354,962, 6,368,234, 6,398,666, 6,413,169, 6,428,426,
6,435,977, 6,623,377, 6,997,821, 7,014,570, 7,101,289, 7,137,907,
7,144,334, 7,258,626, 7,422,528, 7,448,960, 7,713,140, the disclosure of
each of which is incorporated in its entirety herein. The golf club of
the present invention may also have the variable face thickness patterns
disclosed in U.S. Patent Application Publication No. 20100178997, the
disclosure of which is incorporated in its entirety herein.

[0061] Another aspect of the golf club head 40 of the present invention is
directed a golf club head 40 that has a high coefficient of restitution
for greater distance of a golf ball hit with the golf club head of the
present invention. The coefficient of restitution (also referred to
herein as "COR") is determined by the following equation:

e = v 2 - v 1 U 1 - U 2 ##EQU00001##

wherein U1 is the club head velocity prior to impact; U2 is the
golf ball velocity prior to impact which is zero; v1 is the club
head velocity just after separation of the golf ball from the face of the
club head; v2 is the golf ball velocity just after separation of the
golf ball from the face of the club head; and e is the coefficient of
restitution between the golf ball and the club face.

[0062] The values of e are limited between zero and 1.0 for systems with
no energy addition. The coefficient of restitution, e, for a material
such as a soft clay or putty would be near zero, while for a perfectly
elastic material, where no energy is lost as a result of deformation, the
value of e would be 1.0. The golf club head 40 preferably has a
coefficient of restitution ranging from 0.80 to 0.94, as measured under
conventional test conditions.

[0063] The coefficient of restitution of the club head 40 of the present
invention under standard USGA test conditions with a given ball
preferably ranges from approximately 0.80 to 0.94, more preferably ranges
from 0.82 to 0.89 and is most preferably 0.86.

[0064] As defined in Golf Club Design, Fitting, Alteration & Repair,
4th Edition, by Ralph Maltby, the center of gravity, or center of
mass, of the golf club head 40 is a point inside of the club head
determined by the vertical intersection of two or more points where the
club head balances when suspended. A more thorough explanation of this
definition of the center of gravity is provided in Golf Club Design,
Fitting, Alteration & Repair.

[0065] The center of gravity and the moment of inertia of a golf club head
40 are preferably measured using a test frame (XT, YT,
ZT), and then transformed to a head frame (XH, YH,
ZH). The center of gravity of a golf club head 40 may be obtained
using a center of gravity table having two weight scales thereon, as
disclosed in U.S. Pat. No. 6,607,452, entitled High Moment Of Inertia
Composite Golf Club, and hereby incorporated by reference in its
entirety. If a shaft is present, it is removed and replaced with a hosel
cube that has a multitude of faces normal to the axes of the golf club
head. Given the weight of the golf club head 40, the scales allow one to
determine the weight distribution of the golf club head when the golf
club head 40 is placed on both scales simultaneously and weighed along a
particular direction, the X, Y or Z direction.

[0066] In general, the moment of inertia, Izz, about the Z axis for the
golf club head 40 of the present invention is preferably greater than
3000 g-cm2, and more preferably greater than 3500 g-cm2. The
moment of inertia, Iyy, about the Y axis for the golf club head 40 of the
present invention is preferably in the range from 2000 g-cm2 to 4000
g-cm2, more preferably from 2300 g-cm2 to 3800 g-cm2. The
moment of inertia, Ixx, about the X axis for the golf club head 40 of the
present invention is preferably in the range from 1500 g-cm2 to 3800
g-cm2, more preferably from 1600 g-cm2 to 3100 g-cm2.

[0067] From the foregoing it is believed that those skilled in the
pertinent art will recognize the meritorious advancement of this
invention and will readily understand that while the present invention
has been described in association with a preferred embodiment thereof,
and other embodiments illustrated in the accompanying drawings, numerous
changes, modifications and substitutions of equivalents may be made
therein without departing from the spirit and scope of this invention
which is intended to be unlimited by the foregoing except as may appear
in the following appended claims. Therefore, the embodiments of the
invention in which an exclusive property or privilege is claimed are
defined in the following appended claims.